E-bike batteries are sweet until you need to fly a plane. Now, you are traveling and need your e-bike for a solo moment, but you discovered your bike battery can’t go with you. You are wondering why?
These sophisticated batteries are made with high-capacity lithium-ion cells. This is why they violate the strict safety regulations of airlines, either local or international.
An incorrect transportation of your e-bike battery may lead to confiscation, a fine, or even denied boarding. This is exactly why we have decided to discuss how to fly an e-bike battery legally and safely.
What airlines allow it? What other safe alternatives can you use when taking your e-bike with you on an international trip? All these questions are answered in this guide. Are you ready to dive in? Let’s go.
Why E-Bike Batteries Are Restricted on Airplanes
The amount of energy contained in the lithium-ion battery is capable of starting a fire disaster. Especially when short-circuited or overheated.
To avoid such occurrences, the IATA (International Air Transport Association) and the FAA prohibit the carriage of lithium-ion batteries on planes.
Why Can’t You Fly an E-Bike Battery, But Phones Can?
Even though phones and laptops have lithium batteries, they are below the restriction limit of 100Wh. If your question is why other gadgets, such as smartphones and laptops, are allowed, it’s for this reason.
>>> You can also check out this: How to Test E-Bike Battery Voltage with a Multimeter
A standard e-bike battery has a capacity of 400Wh or above, which is beyond the restriction exception value. Hence, it’s a restriction on commercial flights.
Airlines allow lithium-ion batteries with 100Wh. You will require airline approval for lithium batteries with a capacity of 100Wh to 160Wh. Finally, batteries over 160Wh are prohibited, as they are not allowed in the cabin or baggage.
Typical e-bike batteries are:
| Battery | Watt Hours (Wh) | Allowed on Flights? |
| 36V 7Ah | 252Wh | ❌ No |
| 36V 10Ah | 360Wh | ❌ No |
| 48V 12Ah | 576Wh | ❌ No |
| 52V 15Ah | 780Wh | ❌ No |
| 48V 17.5Ah | 840Wh | ❌ No |
The average e-bike battery is 4–8x over the legal limit.
When Are E-Bike Batteries Allowed on Planes?
To travel with your e-bike on a plane, the battery should be below 100Wh. This can be difficult unless you have a small folding e-bike with a custom travel battery.
Another possible way is to split the battery into a module that is below 100Wh. Some brands offer small, removable, travel-customized battery packs.
Finally, it’s possible to fly with special cargo. This is not a common thing with passengers. This applies only to manufacturers.
Alternative Ways to Travel With an E-Bike Battery
Even though you can’t fly with your electric bike battery, there are quick and easy alternatives for you.
1. Ship the Battery Separately via Certified Hazmat Carrier
Any lithium battery with a capacity of 160Wh can be shipped using either FedEx Dangerous Goods or DHL Dangerous Goods. Another popular option is the UPS Hazmat or lithium battery shipping service.
Although there are requirements such as approved fireproof packaging and declaration forms, shipping services require that UN3480 be labeled.
If you are relocating with your e-bike using this service, you are guaranteed to get your battery in 5-10days. Although the cost varies between $120- $400, it is a safe option.
2. Rent a Battery at Your Destination
If your trip is for a few weeks or months, then it is best to rent a battery. Rent e-bike batteries from rental shops and local dealers selling compatible models. Compared to the shipping alternatives, this is a cheaper and stress-free option.
3. Purchase a New Battery When You Land
You can sell your old battery if you travel frequently with your frame. Get a new one on arrival. This is an easier alternative, and it also saves you on the heavy shipping costs.
4. Use an Airline-Approved Travel Battery (Under 100Wh)
If you have the latest folding e-bike model with a detachable, modular 90-100Wh battery, you can fly with it. You will be able to carry at least 2 spare batteries in the cabin. This is because they are not allowed in checked baggage.
How to Pack E-Bike Batteries for Air Travel (If Under 100Wh)
Although it’s impossible to fly a standard e-bike battery on a plane. However, if you do have a legal-size battery, which is rare but possible, you can follow the checklist below:
✔ Pack ONLY in carry-on baggage
Get a good carry-on bag, as your e-bike battery cannot be checked.
✔ Cover the terminals
Ensure that electrical tape is used at appropriate places to prevent short circuits.
✔ Use a fireproof LiPo bag
Get LiPo fireproof bags for your e-bike lithium-ion battery to strengthen your safety measures.
✔ Keep original manufacturer labels
You need your e-bike battery label on it. The manufacturer’s label is what the airline agent will love to check. This is because they need to confirm that the battery capacity doesn’t exceed the required power.
✔ Bring documentation
Have your user manual, airline approval, and a safety sheet ready.
FAQ: Flying With E-Bike Batteries
Why can’t I pack my e-bike battery in checked luggage?
This is to eliminate any form of fire risk. The probability of a successful extinguishing operation for a fire outbreak in cargo is slimmer than you can imagine.
To keep your luggage and every other flight companion safe, it is not allowed.
Can I ship my battery internationally?
Yes, your e-bike battery can be shipped internationally. All you need is a certified Hazmat courier service.
Can I remove cells to reduce the watt-hours?
No. This is not an option as altering the battery cell voids regulations and is also unsafe.
Can I lie about the battery size?
No. Inspections are carried out by airlines using a scan. Once an oversized battery is discovered, it is confiscated and may even result in penalties of any kind.
Can I bring my e-bike and buy a new battery on arrival?
Yes, this is one of the best alternatives. It makes your trip easier. You don’t have to be worried about how long it will take you to get your e-bike battery delivered by a courier service.
Conclusion
Moving your e-bike battery on airplanes requires careful planning. Standard e-bike batteries are not allowed on commercial flights due to their high watt-hour rating. But that doesn’t stop you from transporting your e-bike battery through the alternative route.
Shipping, renting, or outright purchase are all amazing options. Allowing you to enjoy your e-bike legally and safely. For the e-bikes with a battery under 100Wh, follow airline-approved packing rules. Remember to keep your e-bike battery in a carry-on.
